DR-FMEA
The Holistic Approach to Reliability and Safety
DR-FMEA is a software tool that provides a systematic method for
examining each system component to verify that it is applied correctly and to
determine the effect if the component fails. A basic requirement for any product
is that no single component failure can have a catastrophic effect. If you find
such a failure mode, you must find a way to mitigate the effect of failure. This
is best done early in the Design Process.
DR-FMEA stands for “Design
Review - Failure Mode and Effect Analysis”. The user begins with a rigorous
Reliability Stress Analysis for each system component and its application in the
system. The user has the option of including humans as a system component. The
results of the Reliability Stress Analysis are used as the basis for the FMEA.
DR-FMEA includes a
Hazard Factor (H), for each Failure
Mode so that Safety issues can be included in the basic FMEA.
The H factor is the probability of Injury if the
failure occurs. The possibility of Human Error is always present and DR-FMEA
facilitates including Humans and Human Error as components and Failure Modes.
DR-FMEA was designed to be an easy way to verify that the design goals are met
and all failure modes have been identified and mitigated early in the Design
phase. The possible failure modes can be easily expanded to include Human Error,
Instruction Sheets and Compliance with all applicable Codes. DR-FMEA is also an
excellent documenter of the Design Review process.
DR-FMEA answers three basic questions:
Creative
Design is an iterative process so DR-FMEA was designed to follow the evolution
of a design and keep track of the changes along the way. DR-FMEA can be used to
analyze a single assembly or a complex system comprised of many assemblies,
subassemblies and components. DR-FMEA is
also an effective tool for managing the progress of a design and keeping
everyone on the same page.
DR-FMEA uses a Part Number to define
the characteristics of the part and a Parts List to define its function in the
system. DR-FMEA defines
the finished product as the Root-Assembly. Everything else is a component of the
Root-Assembly, has a Part Number, and serves a specific purpose. Some components
of the Root-Assembly may be assemblies of components, some of which may also be
an assembly for many levels. To complicate things further, the
same Part Number may be used many places for different purposes in a design.
To get around this problem, DR-FMEA uses a hierarchical naming
system to provide each component used anywhere in the system a unique name.
Anytime both humans and equipment are
required to make the system work, both should be included as system components
in the analysis. All systems are covered by one or more National Codes or
Standards, which will be the standard that your company will be judged by if
your product becomes involved in a lawsuit.
DR-FMEA allows the user to include
humans, codes, manuals and any other items that that could affect the
reliability or safety of a product. These non-traditional components are
considered part of the product, given Part Numbers and treated like the hardware
components. DR-FMEA also allows the user to expand the definition of a failure
to include anything that can prevent a system from working.
DR-FMEA stores the information in a relational database where it can be
retrieved, sorted and used in many different ways. It has reduced the
information gathering process to four automated worksheets that makes extensive
use of auto-complete fields, data lookup. DR-FMEA automatically generates
related worksheet and transfers the relevant data. We have attempted to reduce
the clerical burden while providing an efficient and easy way to use the tool.
DR-FMEA also generates a meaningful status report, that lists both the resolved
and yet to be resolved design issues.
The Part Number List is where each
part number used in the system is listed along with its capabilities and
limitations. For humans, the Part Number defines a skill-set. The Part Number is
the Identifier used for codes and manuals.
The Parts List is where each
component is entered into the system using its symbol from the drawings. The
drawing or schematic is for a higher level Assembly. The Parts List relates the
Symbol to a Part Number and describes its function in the system. When the Part
Number is entered, the information from the Part Number List is automatically
transferred to the Part List. For Humans the Symbol is the job title. For Codes,
the Symbol is the Name of the Code. The Parts List is where the Reliability
Analysis is performed.
A
FMEA Worksheet is automatically
generated each time a part is entered in the Part List. The basic information
about the part and its application are automatically transferred to the form.
The Failure Mode and Failure Effect are left blank. Having the basic information
about the part on the form greatly simplifies the FMEA process. For humans, the
failure mode is a human error. For
Codes, the failure mode is non-compliance with an article. Each Failure Mode is
evaluated for Safety and is assigned a Hazard Factor
(H). There is a button for additional
failure modes.
Corrective Action Worksheet is derived from the FMEA
Worksheet and is where a person is assigned responsibility for solving a problem
and a date to get it done by.
DR-FMEA uses a Holistic
Approach to Reliability and produces a result that is much greater than the
sum of its parts.
For a complete explanation
showing how easy DR-FMEA is to use:
Download
a copy of our DR-FMEA Users Manual
DR-FMEA is only available
as a download from our web store. Visit
our Web Store
Click Here
to Visit Our Web Site:
For Help or more information, call John Bass at 952/544-6079 or Email: help@BassEngineering.com
Bass
Associates Inc.
13533 Larkin Drive, Minnetonka, MN 55305
Phone: 952/544-6079
Copyright 2009 John M. Bass P.E. Last modified:
March 31, 2010